JP6843551B2 - Methods and systems for sensing the position of the ingot in the mold with a reduced cross-sectional area - Google Patents

Description

(Cross-reference of related applications)
This application claims the interests of US Provisional Patent Application No. 14 / 834,189 filed on August 24, 2015, the entire disclosure of which is incorporated herein by reference.

(Background of the present invention)
In industry, vacuum metallurgical melting systems have been constructed and operated to produce high quality ingots of active or refractory metals and / or their alloys directly from raw materials in a single operating process. It was. In some such systems, the raw material may be provided in an open top and open bottom mold having a heating induction coil surrounding at least a portion of the mold. The raw material (or feed material) can be a metal such as titanium, zirconium, nickel, cobalt, and / or alloys thereof and can be provided in solid or molten form in a mold of a vacuum metallurgy system. When in melted form, these metals can be polluted by oxide refractories commonly used to make inductive melting crucibles. Therefore, to avoid fouling, these metals are typically melted in water-cooled copper containers, but this melting technique is only about 25% efficient thermally.

Ingots, bars and castings with a relatively small cross section of active metal / alloy or refractory metal / alloy made using a vacuum metallurgical melting system are used across the aerospace, automotive, energy and medical industries. ing. These can be machined or forged into a myriad of shapes. These can be used as raw materials that will be stretched into wires or made into powdered metals. Bars with such a small cross-sectional area are typically made from larger ingots that are gradually heated to high temperatures and then forged to the desired size. However, the forging process can lead to significant yield losses (typically 60-70% yield of available metals). This is partly due to the deformation of the end of the ingot after a number of forging steps. In addition, it can take several months for the ingot to wait for its own turn in the forging queue. Even more, due to the relatively small surface area-to-volume ratio of large ingots and the associated cooling rate, the particle size of the final product is more uniform than desired or required. Can be larger or smaller.

Parts made from powdered metals are becoming more and more common and desired. The powdered metal is usually formed by polishing an ingot or casting cast from a molten material or by remelting and spraying. The part can then be produced either by integrating the powder directly into its final form or by integrating it into a preliminary form that is subsequently machined. For most applications, it is usually important that each powder particle has the same composition. This can only be achieved by ensuring that the metal ingot or casting from which the powder is formed is uniform, and this is the case if the molten metal from which the ingot or casting is made is uniform. Can only be achieved.

The most common method for ensuring the uniformity of the molten metal (and / or alloy) is to have the molten metal cast as an ingot before and / or in the mold before injecting the molten metal into the mold. During the time, the molten metal is agitated. Another method is to use an induction coil, which is discussed in US Pat. No. 6,006,821 to Haun dated 28 December 1999, which was assigned to the applicant, which US Pat. Incorporated herein by. Also, an alternative implementation of heating using a single power source with heating elements wirelessly connected in series was assigned to the applicant and filed on September 18, 2013, U.S. Patent Application No. 14/031. , 008, the US patent application is incorporated herein by reference.

Additional complexity due to attempts to cast relatively large ingots made from intermetallic compounds such as titanium, zirconium, nickel, cobalt, aluminum, and / or other metals (such ingots, Small mechanical defects, large mechanical defects, and / or the tendency to fall into catastrophic mechanical defects) can occur. In some cases, a temperature gradient can occur between the outside / surface of the ingot and the inside / core of the ingot as the ingot is cooled after casting and then recovered from the furnace. For some metals and alloys, the rate of cooling and the temperature gradient can be extreme enough or different enough that the ingot can crack, break, or be sheared from itself, it. Makes the ingot incompatible and unsafe for industrial use or post-treatment to make it a relatively small ingot.

For all of these reasons, it is desirable to cast the ingots closer to their desired final cross-section size, a feat that has never been accomplished for small cross-section ingots. .. In addition, it is desirable to ensure that the ingots are as uniform as possible for reasons obvious to those skilled in the art.

U.S. Pat. No. 6,006,821

(Outline of the present invention)
The invention of the present disclosure describes methods and systems for determining the position of an ingot within a segmented water-cooled mold surrounded by an induction melting coil. In particular, the mold and coil assemblies of the present disclosure are used to produce ingots with relatively small or reduced cross-sectional dimensions. Such ingots can be made from complex active or refractory metal alloys such as titanium aluminide or shape memory nickel titanium. Induction heating of the mold and its contents can ensure that high quality ingots (generally free of internal voids and requiring minimal post-formation surface cleaning) can be produced. Partially high quality ingot production is aided by ensuring that the top of the ingot is consistently placed within the optimum zone of the mold for melting. However, in such systems that employ a small or reduced cross-sectional area, there may be only a limited viewing angle within the vacuum metallurgical chamber, thereby visual monitoring of the position of the ingot in the mold. And subsequent control can be problematic. The present disclosure provides structures and means for sensing the position of an ingot in a mold by monitoring the current amplitude or frequency in an induction coil (connected to an induction power source) and in a tuning capacitor. .. The current of the induction melting coil is calibrated to the optimum melting conditions. When additional material is added to the top of the mold, the ingot is moved to keep the current in the induction melting coil within acceptable limits.

In some embodiments, the present disclosure relates to a vacuum metallurgical melting system, which is a segmented mold with an input end and an extraction end that receives a molten metal or alloy and into an ingot. A mold configured to be cast; a primary heating induction coil located at least partially around the segmented mold, configured to direct heat into the internal region of the segmented mold. Primary heating induction coil; a heating power source that is electrically coupled to the primary heating induction coil and powers the primary heating induction coil; electricity including at least the primary heating induction coil, a segmented mold, and a power source. Tuning capacitors configured to tune the circuit; at least one sensing coil located at least partially around the electrical coupling or conductor between the tuning capacitor and the primary heating induction coil; ingots and / or melting An ingot position actuator positioned to support and move a metal or alloy within a segmented mold; and an ingot position controller operably coupled to at least one sensing coil and at least both ingot position actuators. It has an ingot position controller, which is configured to instruct the ingot position actuator to move the molten metal or alloy within a segmented mold.

In some aspects, the vacuum metallurgical melting system provides a material supply that is configured to provide the metal and / or alloy to the input end of the mold segmented in either or both solid and melt forms. Further may be included. The melting system may have a material supply, which is a crucible located near the input end of the segmented mold, providing the molten metal or alloy in a segmented mold. It further includes a crucible configured to do so; a crucible heating system configured to melt a metal or alloy in the crucible; and a secondary power source that is electrically coupled and powered by the crucible heating system. In such an aspect, the crucible heating system may further include a movable plasma arc torch, an electron beam gun, a secondary heating induction coil, or a combination thereof. The segmented template of the melting system can be oriented vertically and may further have segmentation extending along the main axis of the segmented template. The at least one sensing coil provides the ingot position controller with either or both of the electrical coupling between the heating power source and the at least one primary heating induction coil or the power amplitude and power frequency detected in the conductor. It can be configured to translate into an electrical control signal. In addition, the ingot is located in a segmented mold so that the top of the ingot is positioned near the primary heating induction coil, which allows the top of the ingot to be melted or maintained in a melted state. The electrical control signal of the sensing coil can be used by the ingot position controller to automatically steer the ingot position controller for the purpose of moving in. Alternatively, the electrical control signal of the sensing coil is such that the top of the ingot is located near the primary heating induction coil, thereby moving the ingot within the segmented mold so that it melts. It can be read and used through operator interaction to steer the ingot position actuator. In some aspects, the segmented mold can have a cross-sectional area of about 7.1 square inches or less. In other aspects, the segmented mold can have a width or diameter of about 3 inches or less.

In another aspect, the present disclosure relates to a method for determining the position of an ingot within a mold of a vacuum metallurgy system. The method is a step of providing a metal and / or alloy into a segmented mold, wherein the segmented mold is an open top and open bottom mold, step; in a segmented mold. The step of heating the metal and / or alloy to the melting point of the metal and / or alloy using a heating induction coil; keeping the molten metal and / or alloy in a molten state and the metal and / or metal in a segmented mold. Or the step of melting any solid portion of the alloy into a molten state; the step of forming an ingot in a template segmented with a molten metal and / or alloy; and segmented with a sensing coil. It may include a step of determining the position of the ingot in the mold.

The heating induction coil and high frequency power supply are electrically connected to a capacitor, which is used to melt the electrical circuit consisting of the induction coil, the mold and its contents, the capacitor, and the power supply in the mold. It can operate to tune to the optimum power level. In addition, the sensing coil is configured to detect current in the conductor between the heating induction coil and the capacitor, and the current flowing through the induction melting coil and the capacitor induces a proportional current or frequency in the sensing coil circuit. .. In other aspects, the sensing coil may be connected in series with an electronic position controller configured to measure the change in current detected by the sensing coil. In this method, the electronic position controller converts the current detected in the sensing coil into an electrical control signal; the ingot position actuator causes the ingot in the segmented mold to move closer to the heating induction coil. And to keep the top of the ingot in a thawed state. In some aspects, the electronic position controller may command the ingot position actuator through operator interaction. In other aspects, the electronic position controller may command the ingot position actuator via an automatic feedback loop. The method may further comprise melting the metal and / alloy in a primary melting vessel configured to inject a portion of the molten metal and / or alloy into the top of the segmented mold. In other aspects, the method may further comprise the use of a primary supply that is configured to deliver the solid feed material to the top of the segmented mold. In other aspects, the electronic control signal can be used to regulate the power delivered to the heating induction coil, thereby adjusting the degree of heating of the ingot in the mold. In addition, the rate of injection of molten metal and / or alloy into the segmented mold can be adjusted according to the determined position of the ingot in the segmented mold. Finally, the method may include recovering the ingot from the segmented template, and the formed ingot may have a reduced cross-sectional area.
The present specification provides, for example, the following items.
(Item 1)
It is a vacuum metallurgical system, and the above system is
A segmented mold with an input end and an extraction end that is configured to receive a molten metal or alloy and cast it into an ingot.
A primary heating induction coil that is at least partially positioned around the segmented mold and is configured to induce heat within the internal region of the segmented mold. ,
A heating power source that is electrically coupled to the primary heating induction coil and supplies electric power to the primary heating induction coil.
With at least the primary heating induction coil, the segmented mold, and a tuning capacitor configured to tune the electrical circuit including the power supply.
At least one sensing coil located at least partially around the electrical conductor between the tuning capacitor and the primary heating induction coil.
With an ingot position actuator positioned to support and move the ingot and / or molten metal or alloy within the segmented mold,
An ingot position controller operably coupled to at least one of the sensing coils and at least both of the ingot position actuators to the ingot position actuator to move the molten metal or alloy within the segmented mold. A system that includes an ingot position controller that is configured to instruct.
(Item 2)
The system according to the above item, further comprising a material supply configured to provide the metal and / or alloy in either or both solid and melt forms to the input end of the segmented mold.
(Item 3)
The above material supply
A crucible located near the input end of the segmented mold and configured to provide a molten metal or alloy into the segmented mold.
A crucible heating system configured to melt a metal or alloy in the crucible,
The system according to any one of the above items, further including a secondary power source that is electrically coupled to the crucible heating system and supplies power to the crucible heating system.
(Item 4)
The system according to any one of the above items, wherein the crucible heating system further includes a movable plasma arc torch, an electron beam gun, a secondary heating induction coil, or a combination thereof.
(Item 5)
The system according to any one of the above items, wherein the segmented mold has segmentation that is oriented vertically and extends along the main axis of the segmented mold.
(Item 6)
The at least one sensing coil transfers any or both of the current amplitudes and current frequencies detected in the electrical conductor between the heating power source and the at least one primary heating induction coil to the ingot position controller. The system according to any one of the above items, which is configured to convert to an electrical control signal provided.
(Item 7)
The electrical control signal of the sensing coil is such that the top of the ingot is positioned near the primary heating induction coil, thereby moving the ingot within the segmented mold so that it is melted. , The system according to any one of the above items, used by the ingot position controller to automatically steer the ingot position actuator.
(Item 8)
The electrical control signal of the sensing coil is such that the top of the ingot is positioned near the primary heating induction coil, thereby moving the ingot within the segmented mold so that it is melted. , The system according to any one of the above items, which is used through operator interaction to steer the ingot position actuator.
(Item 9)
The system according to any one of the above items, wherein the segmented mold has a cross-sectional area of about 7.1 square inches or less.
(Item 10)
The system according to any one of the above items, wherein the segmented mold has a width of about 3 inches or less.
(Item 11)
A method for determining the position of an ingot in a mold of a vacuum metallurgy system, the above method
By providing the metal and / alloy in a segmented mold, the segmented mold is an open top and open bottom mold.
Heating the metal and / or alloy in the segmented mold using a heating induction coil and
To keep the molten metal and / or alloy in a molten state and melt any solid portion of the metal and / or alloy in the segmented mold into a molten state.
Forming an ingot in the segmented mold using the molten metal and / or alloy
A method comprising locating the ingot within the segmented mold using a sensing coil.
(Item 12)
The heating induction coil and the high frequency power supply are electrically connected to the tuning capacitor, and the above method
The method of the above item, further comprising tuning an electrical circuit consisting of the induction coil, the mold and its contents, and the power source to an optimum power level for melting in the mold.
(Item 13)
The sensing coil is configured to detect current in the conductor between the heating induction coil and the tuning capacitor, and the current flowing through the induction melting coil and the tuning capacitor has a proportional current or frequency in the sensing coil circuit. The method according to any one of the above items for inducing.
(Item 14)
The method according to any one of the above items, wherein the sensing coil is connected in series with an electronic position controller configured to measure a change in current detected by the sensing coil.
(Item 15)
The electronic position controller converts the current detected in the sensing coil into an electrical control signal.
Instructing the ingot position actuator to move the ingot in the segmented mold closer to the heating induction coil.
The method according to any one of the above items, further comprising maintaining the top of the ingot in a molten state.
(Item 16)
The method according to any one of the above items, wherein the electronic position controller commands the ingot position actuator via an operator interaction.
(Item 17)
The method according to any one of the above items, wherein the electronic position controller commands the ingot position actuator via an automatic feedback loop.
(Item 18)
The electronic position controller converts the current detected in the sensing coil into an electrical control signal.
The item according to any one of the above items, further comprising adjusting the power supplied to the heating induction coil to change the degree of heating of the metal and / or alloy in the segmented mold. Method.
(Item 19)
The item of the above, further comprising adjusting the injection rate of the molten metal and / or alloy into the segmented mold based on the determined position of the ingot in the segmented mold. The method according to any one item.
(Item 20)
The method according to any one of the above items, further comprising recovering the ingot from the segmented mold, wherein the ingot has a reduced cross-sectional area.
(Summary)
A system and method for sensing the position of an ingot within a segmented mold of a vacuum metallurgical system. The induction sensing system measures the variation in current between the power source and the load of the induction heating coil. The system and method are particularly suitable for determining the position of the ingot in the mold of the melting system, especially if the mold has a relatively reduced or relatively small cross-sectional area.

Illustrative aspects of the present disclosure are described in detail below with reference to the drawings below.
FIG. 1A is a schematic representation of a first embodiment of a vacuum metallurgical system for forming an ingot according to aspects of the present disclosure. FIG. 1B is a schematic representation of a second embodiment of a vacuum metallurgical system for forming an ingot according to aspects of the present disclosure. FIG. 1C is a schematic representation of an embodiment of a vacuum metallurgical system for forming the ingot shown in FIG. 1B, according to aspects of the present disclosure. FIG. 2 is a flow chart illustrating the process for forming an ingot using a guidance sensing system according to aspects of the present disclosure. 3A-3G are various views of segmented molds for vacuum metallurgy systems according to aspects of the present disclosure.

To provide a complete understanding of the many embodiments disclosed herein, a number of specific details are provided throughout this description for illustrative purposes. However, it may be apparent to those skilled in the art that many embodiments can be implemented without some of these particular details. In other examples, known structures and devices are shown in diagram or schematic format to avoid obscuring the underlying principles of the embodiments described.

The present disclosure relates to a system and method for determining the position of an ingot within a mold of a melting system (particularly a vacuum metallurgical melting furnace system), which is the structure, configuration, and / of the mold as part of the system. Or due to other design requirements, it cannot be easily observed. An exemplary embodiment provides, among other things, a system and method comprising a guidance sensing system for determining the position of an ingot within a segmented template (also referred to as an alternative tundish). Accurate maneuvering of the ingot in the mold by knowing the position of the ingot in the mold (eg, adjusting or changing the position of the ingot in the mold, or heating the heating device in the melting system directed at the mold. (Changing the characteristics) becomes possible. The present disclosure is believed to be particularly useful for forming ingots of standard size traditionally known in the art or ingots with a reduced cross-sectional area. The present disclosure is also believed to be useful for forming ingots and / or castings that can subsequently be converted to powders (of interest in the uniformity of each fine particle of the powder). In addition, the present disclosure is believed to be useful for forming ingots and / or castings for standard production, or elongated castings. In many aspects, the present disclosure is considered particularly suitable for forming ingots composed of titanium, zirconium, nickel, cobalt, aluminum, and combinations and alloys thereof.

Throughout this disclosure, the terms "reduced cross-section", "small cross-section", and "standard size" are used as being based on the size of their cross-section relative to each other and in industry. As used. As used herein, a "reduced cross section" and / or a "small cross section" is an ingot or casting having a width or diameter of about 3 inches (3 inches) or less, and / or typically. Refers to an ingot or casting having a cross-sectional area of 7.1 square inches or less (≦ 7.1 sq in). For example, a mold with a reduced cross-section can produce a circular cross-section ingot with a diameter of about 3 inches or less (≤3.0 in). Additional or alternative, the terms "reduced cross-section" and "small cross-section" have the following effects: avoiding cracking in the final ingot; during further production to the final product. Avoiding cracking of the ingot when it is being processed; allowing controlled cooling while the ingot solidifies; eg relatively small particle size (eg 100 micrometers or less) Any suitable size template may be referenced to achieve any one or more of the production of ingots having any desired particle size, such as.

In addition, as used herein, "standard size" is an ingot or casting with a width or diameter of about 3-6 inches (3-6 inches) or larger, and / or typically. Refers to ingots and / or castings having a cross-sectional area greater than 7.1 square inches (> 7.1 sq in). Additionally, as used herein, "metal / alloy" is used to refer abbreviated to "metals, intermetallic compounds, and / or alloys" and variants thereof.

In particular, aspects of the present disclosure provide systems and methods for producing ingots with a reduced cross-sectional area. Raw materials for metals and / or alloys are fed into segmented molds. The metal / alloy raw material can be supplied in solid form or in molten form dissolved in a container such as a crucible. Induction coils provided around or below the vessel provide electromagnetic heating and / or agitation of the molten metal / alloy within the segmented mold. When the metal / alloy is fed into a segmented mold in solid form (eg, via a primary feed section such as a bar feed section), the induction coil can dissolve the raw material in melt form. Stirring of the molten metal / alloy when the ingot is formed, and consistent heating of a particular region of the molten metal / alloy, results in better uniformity of the molten metal / alloy when compared to other known systems. Can be connected.

In some implementations of vacuum metallurgical melting systems with open top and open bottom segmented molds, the ingots cast in the mold are heated, at least partially aligned around the segmented mold. The induction coil is removed from the bottom of the mold while the top of the ingot remains in a molten state. In some aspects, the open top of the mold can be referred to as the input end and the open bottom of the mold can be referred to as the extraction end. By keeping the top of the ingot in a segmented mold, the additional molten metal / alloy added to the ingot is more likely to form a strong uniform bond, thereby minimizing it. It is more likely to be part of an ingot with mechanical defects or other unwanted deficiencies. Therefore, heating the top of the ingot is advantageous for producing high quality ingots in a single or continuous operation, regardless of where the ingot is located within the segmented mold. ..

A melting vessel (alternatively also referred to as a crucible) is used to dissolve the metal / alloy of the feed material into the molten metal / alloy before the feed material is fed into the segmented mold. Can be used. The feed material enters the dissolution vessel with the dissolution vessel in the supply and / or dissolution position by appropriate means (eg, pushed by the bar supply or dropped by the bulk supply). .. In some embodiments, the plasma arc torch dissolves the feed material in a melting vessel that maintains an undissolved skull at the bottom and a melting pool at the top. The melted contents of the melting vessel are moved into the mold by moving the melting vessel to the delivery position and injecting the melted contents (alternatively also referred to as "dissolved matter") through the injection notch. Can be transferred. Once the melted contents of the dissolution vessel have been transferred, the dissolution vessel can be returned to the supply and / or dissolution position and the more solidified material is directed into the dissolution vessel for subsequent dissolution. ..

In another embodiment, an electron beam gun can be used to melt the metal and / alloy in a water-cooled copper melting vessel. The water-cooled copper melting vessel can then incline the molten metal / alloy into the mold. In a further embodiment, the melting vessel can be an induction melting crucible, which is separate from the induction heating coil (separate from the induction heating coil coupled to the segmented mold) to melt the metal and / alloy. Can be combined with different ones). The inductive melting crucible can be tilted to inject the molten metal / alloy into the mold. In the above embodiment, each of the plasma arc torch, the electron beam gun, and the induction heating coil for the melting vessel / crucible can be powered by a power source dedicated to melting the feed material. In embodiments where the feed material is a melting material, the melting material spills into a small cross-sectional area size mold with minimal spills (eg, spills through the injection notch at one end of the melting vessel). Be directed. For a mold with a reduced cross-sectional area, if a directional heat source (eg, plasma arc torch, etc.) is used to heat the material at the top of the mold, the diameter of the plasma arc will destroy the mold itself. Can be large enough to take the risk of doing so.

In an alternative embodiment, the feed material provided to the segmented mold can be a metal / alloy in solid form, which is dissolved within the segmented mold. In some aspects, the metal / alloy is placed in a segmented mold by a directional heating device (eg, a plasma arc torch or electron beam gun located above the open top of the segmented mold). Can be dissolved. In other aspects, the metal / alloy can be melted in the segmented mold by a heating induction coil that is partially positioned and arranged around the segmented mold.

The segmented mold is typically made from copper and can be water-cooled internally, at least inside the mold to allow fluid to pass through and to provide a heat exchange conduit. It has a channel that extends through a portion. In some embodiments, the segmented mold has a small cross-sectional area (which, in some implementations, can be less than about 7.1 square inches). The aspect ratio of the mold (ie, the internal length divided by the inner diameter) can range from about 2: 1 to about 10: 1. In some exemplary embodiments, the segmented water-cooled mold can have an inner diameter of about 53 millimeters (53 mm). In other embodiments, the segmented water-cooled mold may have an inner diameter of about 50 mm to about 102 mm (~ 50 mm-102 mm) within that range, in any increment, gradient.

Power can be delivered to an induction coil that surrounds a portion of the template segmented by a high frequency inductive power source. Tuning capacitors can be used to tune the load to a power source for optimal power input and melting performance (load generally includes a segmented mold, an ingot housed therein, and a coil. However, it is considered that they are not limited to them). In some aspects, the tuning capacitor can be varied by adding capacitors. Tuning the load to avoid impedance mismatch with the power supply can optimize the thermal input with the least amount of input power.

During the casting process, the ingot is recovered from the bottom of the mold, but the top of the ingot near the induction coil remains in a molten state. Due to the relatively small inner diameter of the segmented molds discussed herein and the limited viewing angle from the wall (or lid) of the vacuum metallurgical chamber, the observer or operator can see. It can actually be difficult to pinpoint the position of the ingot in the mold by means of the tool. However, at a fixed power input to the induction coil, the ingot uses a sensing coil (also also referred to as a sensor induction coil) to monitor the circulating current between the induction coil and the tuning capacitor. , Can be electrically sensed. Due to the high frequency current oscillating between the induction coil and the tuning capacitor, an electrically isolated sensing coil can be used to measure that current. The sensing coil is placed around one of the leads to the induction coil that surrounds the segmented mold. The sensing coil can be mounted outside the vacuum metallurgical chamber, but can be mounted between the tuning capacitor and the induction coil. The sensing coil is then electrically connected to a current meter rated for the high frequency current delivered by the inductive power supply. This can be referred to as a guidance sensing system.

When the position of the top of the ingot changes within the mold either by physically moving the ingot downwards with a suitable manipulator or by adding the melting material from the melting vessel to the top of the mold. In addition, the current of the induction coil changes. Given that the inductive power source is operated in constant power output mode, the coil current will fluctuate in a predictable manner from the tuned and calibrated values required for optimum melting conditions. When the mold (or the relevant section of the mold) is completely full, the induction coil current reaches a low value. When the mold (or the relevant section of the mold) is nearly empty, the induction coil current reaches a high value. Therefore, based on current measurements (which can be measurements of current amplitude and / or current frequency, or both), and an understanding of how the ingot is injected into the mold, and / Alternatively, the position of the ingot in the mold can be determined based on an understanding of how the ingot is recovered from the mold. Depending on the stage of the ingot casting process, the ingot can be further moved within the mold to the desired location for a particular processing operation. Similarly, the rate of injection of feed material into the mold can be adjusted based on the determined position of the ingot in the mold.

In both FIGS. 1A and 1B, the entire system 100 is based on the vacuum metallurgical chamber 102. A material supply 104 and a water-cooled mold 106 are present in the vacuum metallurgical chamber 102. The material supply 104 may be part of a system in which the material (metal / alloy) in the material supply 104 is melted before being delivered to the segmented mold 106. In various aspects, the material supply 104 may be placed entirely inside the vacuum chamber 102, outside the vacuum metallurgical chamber 102, or as a port on the wall of the vacuum metallurgical chamber 102. In some aspects, the segmented mold 106 can be a water-cooled mold. In many embodiments, the segmented mold 106 is an open bottom mold oriented vertically within the vacuum metallurgical chamber 102. The heating of the material supply may have a supply heating power source 108. The supply heating power source 108 may supply power to various heating devices. In the first embodiment shown in FIG. 1A, the feed heating power source 108 may power the secondary heating induction coil 110, which may heat the metal / alloy supply through the induction. .. In a second embodiment shown in FIG. 1B, the heating power source 108 may power the directional heating device 112, which in various embodiments is a movable plasma arc torch or electron beam gun. Can be. Either the secondary heating induction coil 110 or the directional heating device 112 can be used individually or in combination for any given system 100. In some embodiments, the metal / alloy is fed as a melt 105 from the material supply 104 to the segmented mold 106 in a melted form. In other embodiments, the metal / alloy is provided in raw (solid) form from the material supply 104 to the segmented mold 106. In a further embodiment, the lysate 105 can be further processed, for example, in an intermediate vessel such as an additional specialized melting hearth, or in one or more purification hearths (not shown).

Accurate melting and mixing of raw metal / alloy materials is crucial where alloy ingots or other castings are desired. Achieving the desired mixing means that the volume of the material supply 104 is large enough to hold individual fragments of the raw material during dissolution and the metal / alloy is effectively premixed to be raw material specific. It can be facilitated if it is large enough to stabilize any small compositional variation per fragment. The desired mixing can be further achieved by deliberately emptying the material supply 104 on a regular basis, leaving a minimum amount of skull, in order to avoid the accumulation of high melting point elements, components, or alloys.

When the material from the material supply 104 is provided in the segmented mold 106, the melted material can remain in a molten state or the solid material from the material supply 104 (or any residue of the solid material). Is melted into a thawed state, forming the ingot 114. The ingot is formed in the water-cooled mold wall 116. A water source 118 with inlets and outlets is provided, connected to a segmented mold 106 and extends through at least a portion of the interior of the mold wall 116.

The ingot position actuator 120 may move the ingot 114 within the water-cooled mold 116. In some aspects, the ingot position actuator 120 has a recovery head 122 in which the metal / alloy is first received regardless of whether the metal / alloy is received from the material supply 104 as a solid or melt. It is configured to receive the ingot 114 as it enters the template 106 segmented into. In various embodiments, the recovery head 122 can be a dovetail head, a threaded head, a tapered head, or a threaded tapered head. The ingot position actuator 120 may mechanically move the ingot 144 up and down within the segmented mold 106 and retract so that the ingot 114 is completely recovered from the segmented mold 106 and the vacuum metallurgical chamber 102. obtain.

The segmented mold 106 can have a variety of cross-sectional shapes, in particular the segmented mold 106 has a circular cross-section, a polygonal cross-section, or a polygonal cross-section with rounded corners. Can be done. Furthermore, the segmented mold 106 is not limited to a constant cross-sectional size or cross-sectional shape. Alternatively, the segmented mold 106 can be tapered. A given segmented template 106 used for the disclosed process may have any one of many different possible shapes, depending on the desired article. The segmented mold 106 can be molded to form a particular part or multiple parts, or to form any preformed shape that can be transformed into a particular part or multiple parts. Can be done. In other aspects, the space between the segments of the segmented mold 106 extends vertically along the main axis of the segmented mold 106 or bands along the main axis of the segmented mold 106. It may extend horizontally within or in a repetitive or regular pattern around the outside of the segmented mold 106.

The ingot 114 is kept partially melted and / or melted by a primary heating induction coil 124 that keeps at least a portion of the ingot 114 in a melted state through induction. In some aspects, the primary heating induction coil 124 is capable of heating the ingot 114 by eddy currents passing through the configured gaps of the water-cooled segmented mold 106. In various embodiments, the primary heating induction coil 124 may surround or be coupled to the entire segmented template 106 or the region of the segmented template 106. The primary heating induction coil 124 is electrically coupled to the primary heating power supply 126 through the primary electrical connection 128 and is powered by the primary heating power supply. The primary heating power supply 126 can be either an AC power supply or a DC power supply, and employs a power inverter or a power converter as needed. The tuning capacitor 142 may be located in the circuit between the primary heating power supply 126 and the primary heating induction coil 124 and may be operational to tune the electrical load of the system.

The sensing coil 130 may be positioned to surround at least a portion of the primary electrical connection 128 between the primary heating induction coil 124 and the tuning capacitor 142. The sensing coil 130 only needs to be located around one of the leads of the primary electrical connection 128 between the primary heating power supply 126 and the primary heating induction coil 124. The sensing coil 130 is an induction coil that can detect and measure fluctuations in the current of the primary heating induction coil 124 carried by the primary electrical connection 128 when the load of the system changes. In particular, the current flowing through the primary heating induction coil 124 and the tuning capacitor 142 induces a proportional current or frequency in the sensing coil 130 circuit, and the proportional current or frequency indicates a change in the load of the primary heating induction coil 124 circuit. .. The sensing coil 130 has a structure separate from that of the primary heating induction coil 124, and does not have a role of supplying electric power to the primary heating induction coil 124 or a role of adjusting the primary heating induction coil 124. In some embodiments, the sensing coil 130 may be a single set coil positioned around the primary electrical connection 128, whereas in other embodiments the sensing coil 130 is along the primary electrical connection 128. It can be a series or multiple individual coils arranged. Further, the sensing coil 130 may be arranged outside the vacuum metallurgical chamber 102.

The electronic position controller 132 can be electronically coupled to and communicate with the sensing coil 130, the ingot position actuator 120, and the mold sensor 138. The sensing coil 130 may provide a feedback signal 134 to the electronic position controller 132, which indicates the current of the primary heating induction coil 124. The electronic position controller 132 may include a current meter for the purpose of measuring fluctuations in the current detected by the sensing coil 130. The mold sensor 138 can be coupled to the segmented mold 106 and can measure the characteristics of the mold (eg, temperature, etc.). In addition, the template sensor 138 can be coupled to a video device, which is configured to observe the top of the segmented template 106 and monitor the formation of the ingot 114. Based on the signals and measurements received by the electronic position controller 132, the electronic position controller 132 may transmit a control signal 136 to the ingot position actuator 120 and into the ingot position actuator 120 within the segmented mold 106. The position of the ingot 114 may be ordered to rise, fall, and / or maintain. In some aspects, the electronic position controller 132 may include an auto-closed-loop electrical control device, which ultimately comprises the fluctuation of current provided by the feedback signal 134 of the sensing coil 130. Is configured to operate the ingot position actuator 120 using the electrical control signal 136.

The control interface 140 can be coupled to various components of the system 100 and can control these various components. The control interface 140 may include a microprocessor and a processing device capable of controlling the operation of the appliance and recording the measurement of the system. The control interface 140 may further include one or both of a user interface and an automated control system for control by a human operator. The feed heating power supply 108, the primary heating power supply 126, the electronic position controller 132, and the control interface 140, which is electronically coupled directly or observably to the ingot position actuator 120, are of the ingot 114 in the segmented mold 106. It can be used to command and control the position, the amount of metal / alloy in the segmented mold 106, and the intensity or intensity of the energy produced by the primary heating induction coil 124. In addition, the control interface 140 may be electronically coupled directly or indirectly to any or all of the material supply 104, the secondary heating induction coil 110, and the directional heating device 112, of a metal / alloy material. It can operate to control the melting and input of the metal / alloy into the segmented mold 106. The control interface 140 can also be used to characterize the system 100, establish a baseline for current measurements, and variations from that baseline can be used to determine the location of the ingot within the mold wall 116.

At the time of application, the tuned system 100 is set to optimized melting conditions and ingot 114 casting conditions. When the metal / alloy is added to the segmented mold 106, the load on the system changes and the corresponding change in the current of the primary heating induction coil 124 carried by the primary electrical connection 128 is measured by the sensing coil 130. Will be done. Generally, in a situation where the measurement area of the segmented mold 106 is completely filled with metal / alloy, the current of the primary heating induction coil 124 reaches the lowest value; therefore, the measured current When low, the position of the ingot within the segmented mold 106 is high. Conversely, when the measurement area of the segmented mold 106 is almost empty, the current of the primary heating induction coil 124 reaches the highest value; therefore, when the measured current is high, within the segmented mold 106. The position of the ingot 114 is low. The minimum and maximum current measurements depend on the region of the segmented mold 106 heated and surrounded by the primary heating induction coil 124, as well as the tuning and calibration of the reactor system 100.

In some embodiments, the segmented template 106 may have a segmented temperature control system, the segmented temperature control system where the segmented template 106 is, for example, particularly a melting material. Allows to be cooled at the bottom (eg, by the water source 118) and heated at the top (eg, by the primary heating induction coil 124) when fed into the mold. This maintains a certain depth of molten material above the portion of the material that is in the solidification process at any given time. The pressure created by this melting head can help ensure the formation of the ingot 114 without holes or other imperfections (eg, coagulation shrinkage voids). In addition, the constant mixing effect formed by the primary heating induction coil 124 can help ensure a chemically uniform melting pool, thereby providing chemical uniformity over the length of the ingot 114. The degree can be guaranteed. Also, some of the solidified material of the ingot 114 can be remelted by the melting head and mixed using the melting head, adding to the uniformity of the ingot 114.

Based on the measured current values, the furnace system 100 can be controlled or manipulated to take further action, depending on the processing stage of the casting. For example, if the measured current is at or near the highest value and the ingot 114 is towards the bottom of the segmented mold 106, indicating that the segmented mold 106 is empty, then the metal / alloy. Can be added to the ingot 114 to form longer castings. Similarly, if the measured current is at or near the lowest value, indicating that the ingot 114 fills most or all of the segmented mold 106, the addition of additional metal / alloy is stopped and the ingot The position actuator 120 can be operated to move the recovery head 122 downwards and pull the cast ingot 114 out of the open bottom of the segmented mold 106. Similarly, the power provided to the primary heating induction coil 124 can be adjusted based on the position of the ingot 114 within the segmented mold 106.

Thus, in any of the continuous, semi-continuous, batch, or iterative modes of manufacture, the ingot position actuator 120 accurately adds feed material capable of binding to the ingot 114 to the top of the segmented mold 106. As a result, the ability of the ingot to allow it to have a uniform particle structure allows the cast ingot 114 of the desired length to be withdrawn from the segmented mold 106.

FIG. 1C is a schematic representation of an embodiment of a vacuum metallurgy system for forming an ingot, as a generalized view of a vacuum metallurgical chamber 102 with a directional heating device 112, as shown in FIG. 1B. , Represents the furnace system 100. Further illustrated is a material supply actuator 144, which is configured to provide a raw material for making an ingot 114 in a mold 106 segmented into a material supply 104. Further illustrated is the ingot recovery chamber 146, which can be coupled to the vacuum metallurgical chamber 102, through which the ingot position actuator 120 moves the ingot 114 from the vacuum metallurgical chamber 102. It can be recovered and the cast ingot 114 can be removed from the recovery chamber for further industrial use or processing. Further, the primary heating power supply 126 is shown, and the primary electrical connection 128 and the sensing coil 130 may be housed in the housing of the primary heating power supply 126 or in the housing connected to the vacuum metallurgical chamber 102.

FIG. 2 is a flow chart showing the process for forming an ingot using a guidance sensing system. In step 200, a material supply is prepared, the material supply comprising an active or refractory metal alloy or a combination thereof. Raw materials for material supply are prepared in individual quantities so that their composition is within acceptable limits for the desired mixture or alloy. Common forms of raw material are small discs; cylinders; blocks; loose materials that are packaged in foil to form spheres; unwrapped loose materials; scrap fragments of the desired metal; of metals or alloys. Contains the mixture. However, the raw material can be in any suitable form. This allows the raw material to be fed by any suitable method (eg, pushed by the bar feeder, dropped by the bulk feeder, or, in the case of disjointed materials, through a hopper or spoon-shaped canister. , Then it is dropped into the crucible / container) to enter the crucible / container.

In step 202, the material supply metal / alloy may include, but is not limited to, heating means (plasma arc torch, electron beam gun, or induction heater) for heating the material supply held in the material supply crucible. ) Dissolves in a melted state. Accurate dissolution and mixing of raw materials is crucial for situations where alloy ingots are desired. Therefore, the volume of the crucible / container that holds the material supply is large enough to hold the individual pieces of raw material during melting, while at the same time effectively premixing the alloy, each piece unique to the raw material. It should be large enough to stabilize any small compositional variation. This can be further achieved by deliberately emptying the crucible / vessel regularly, leaving a minimum amount of skull, in order to avoid the accumulation of high melting point elements, components, or alloys. Crucibles / containers are not intentionally used to refine alloys, so relatively long endurance times are not required. Inclined injection of the crucible / vessel can allow for rapid raw material turnover, which can allow the formation of a nearly uniform liquid that is subsequently delivered to the mold.

In step 204, the material feed metal / alloy is provided to the mold as part of a tuned system and the metal / alloy is either in the solid state (from step 200) or in the molten state (from step 202). Can be received at. In an embodiment in which the material supply is melted before it is delivered to the mold, when a sufficient amount of metal / alloy is melted and collected at the top of the container, the container will charge the desired amount of molten material to the mold. Tilt by any suitable actuator to inject into. The material can be injected in individual quantities or in batches. In an alternative embodiment of the process, the metal / alloy received in the molten state can retain the residue of the solid feed material. In step 206, the metal / alloy can be heated in the mold via an induction heating coil that surrounds or is near the mold. The induction heating coil can be powered to keep the metal / alloy in a molten state while at the same time melting any solid piece of material feed in the mold. This causes the molten metal / alloy to form an ingot in the mold or join the ingot in the mold. In step 208, the current between the induction heating coil and the power source that powers the induction heating coil can be measured for variations that indicate changes in the load of the induction heating coil and the circuitry formed by that power source. Generally, at least one sensor coil is positioned to measure the current between the induction heating coil and its power source, and either or both of the current amplitudes and current frequencies detected at that current are used in the controller system. It is configured to be converted into an electrical control signal provided in. In step 210, the position of the ingot in the mold, especially the vertical location of the ingot, can be determined based on the variation in current between the ingot heating coil and its power source.

In step 212, the location of the ingot in the mold can be adjusted, for example, by a physical actuator to raise, lower, or otherwise position the ingot in the mold. The ingot has the additional metal / alloy in the mold to receive the additional metal / alloy near the induction heating coil, for example, so that the additional metal / alloy can bond with the ingot in the desired manner. It can be moved within the mold for the purpose of allowing it to be added. In other words, the top of the ingot is positioned near the primary heating induction coil, either automatically based on the feedback signal from the sensing coil or manually through operator interaction, thereby melting. It is maintained or allowed to melt. Alternatively, the ingot can be moved to retrieve the ingot from the mold. In other words, after a certain amount of metal / alloy has been injected into the mold, the ingot is moved downwards to allow the next amount of material to be injected into the mold. Provides a larger open space at the top of the. Therefore, the ingot is a mold by pulling the solidified portion of the ingot out of the bottom of the mold using any suitable means (eg, hydraulic cylinder, movable clamp, puller head, or drive roll, etc.). It is reduced either continuously or gradually within. Also, the ingot can be raised in the mold as needed to continue the formation or stretching of the ingot. The process can return from step 212 to step 204 to add additional metal / alloy to the mold, which can increase the length of the ingot. Alternatively, the process can proceed from step 212 to step 214, in which the ingot is removed from the mold.

It can be understood that ingots cast according to the methods of the present disclosure may have a small cross-sectional area of about 7.1 square inches or less. In addition, exemplary ingot sizes can be about 21/8 inch in diameter and 120 inches or larger in length. The ingots produced by the methods of the present disclosure can be very close to the desired final size and shape, and a minimal amount of machinery to remove unwanted as-cast features related to how the ingots solidify and cool. Only processing is required. In other words, this process may provide a small diameter ingot that requires minimal outer diameter surface machining, if any, with the goal of producing a bar with the desired surface finish. In addition, ingots cast according to the methods of the present disclosure can be produced more consistently and repeatedly with the desired surface finish, improving both the product and the efficiency of the method and system. In addition, the surface area to volume ratio of the ingot with a small cross-sectional area and the associated cooling, as well as the temperature gradient established within the ingot, have as-cast of the desired particle size suitable for post-treatment applications. Can lead to ingots. Therefore, some ingots produced by this process can be forged under as-cast conditions. In some examples, titanium alloy ingots can have an as-cast particle size of about 100 micrometers (100 mm) or less.

3A-3G are various views of segmented water-cooled molds for the furnace system. Specifically: FIG. 3A shows a side view of the segmented mold; FIG. 3B shows a top view of the segmented mold; FIG. 3C is the line shown in FIG. 3B. A side sectional view of the segmented mold along B is shown; FIG. 3D shows a lateral sectional view of the segmented mold along line A shown in FIG. 3A. 3E shows a cross-sectional view from above of the segmented mold along line C shown in FIG. 3A, and further shows the space in the mold that can receive the water-cooled structure. FIG. 3F shows a cross-sectional perspective view of the segmented mold; and FIG. 3G shows a perspective view of a water-cooled structure that can be coupled to the mold.

(Exemplary ingot position calibration data)
Tables 1A-1D below record the exemplary data collected to determine the relationship between the top of the ingot lysate and the position of the ingot in the mold. The already melted ingot stub was cut and placed at a specific distance from the top of the mold. The induced power was gradually increased and the tank circuit was measured using the Rogowski Belt and its associated digital reading. The inductive power supply is set to a "constant power" mode of operation, which mode is shown as the maximum percentage (100%) of the power output. After the test was completed, the chamber was opened, the ingot was removed and a visual examination of the ingot was performed.

The system used for the test included a Pillar Mark 5 power supply operated at 150 kW, a PAM-5 signal modulator, and a mold with an inner diameter of 53 mm (53 mm), in which an ingot was cast. .. Table 1A provides tests obtained from metal stubs with a length of 5 1/8 inch, located 7 1/8 inch from the top of the mold. Table 1B provides tests obtained from metal stubs with a length of 37/8 inches located 8 1/2 inches from the top of the mold. Table 1C provides tests obtained from metal stubs with a length of 7 inches, located 5 1/4 inch from the top of the mold. Table 1D provides tests obtained from a 6 inch long metal stub located 6 inches from the top of the mold, where the additional charge of metal is dissolved and as part of the ingot in the mold. Added for casting.
The metal stub used for the test consisted of a titanium-niobium-molybdenum (TNM) alloy. The induction coil that heats the material in the mold was located near the open top of the mold.

Generally, the test shows that when the mold is emptied, the circuit current between the induction heating coil and its power supply (alternatively also referred to as "tank circuit current") is about 1, It was shown that the maximum value of 650 Amp can be reached. When the top of the ingot was higher in the mold, the tank circuit current was at a baseline value of about 1,510 Amp. When the ingot was cast (reflected in Table 1D), by continuously injecting from the hearth and collecting the ingot as appropriate, lower tank circuit current readings were observed, with the lowest recorded reading being 1, It was 420 Amp.

Positioning the stub 7/8 inch from the top of the mold, as can be seen in Table 1A, resulted in a small melting pool at the top of the ingot. This indicates that the stub was positioned lower in the mold with respect to the induction heating coil. A small melting pool at the top of the ingot would not necessarily be sufficient or ideal for addition to the cast ingot. Positioning the stub 8 1/2 inches from the mold length, as can be seen in Table 1B, barely resulted in the top of the melting ingot. This reinforces the suggestion that the stub was positioned very low in the mold with respect to the induction heating coil. As can be seen in FIG. 1C, positioning the stub 5 1/4 inch from the top of the mold results in a completely molten ingot top, which results in additional metal / alloy for casting the ingot. Ready to add.

For the tests shown in Table 1D, additional action was taken during the period when the system power was set to 85%. Specifically: At 17.5 minutes, the plasma arc torch was started; at 19 minutes, the metal charge in the hearth was melted using the plasma arc torch; 22.5. At the time of the minute, the charge in the hearth was determined to be completely melted and subsequently added to the mold for casting the torch. The test shown in Table 1D, that is, positioning the stub 6 inches from the top of the mold and injecting additional melting material into the mold resulted in a cast ingot with a length of approximately 600 nm. .. The ingot had an acceptable as-cast surface finish for post-treatment applications.

Subsequent ingot casting tests revealed that the tank circuit current reading was approximately 1,350 Amp (at 85% induced power supply setting) when the melting pool was near the top of the mold. .. However, the melting pool began to solidify due to the lack of proper power input. In other words, if the ingot was positioned very high in the mold, the load on the circuit was not optimized, thereby moving the power supply out of its optimal melting range.

It is understood that the exemplary data provided herein are not limited to the disclosed structural details. Rather, allowing the top of the ingot to be completely melted in the mold so that additional metals / alloys can be uniformly bonded to the ingot is consistent with the present disclosure of ingot length, metal. And can be achieved using alloys, power settings, duration of heating, and composition of the components of the melting system.

Further, it is understood that the measured fluctuations in current can fluctuate based on the composition of the metal / alloy being melted. For example, an exemplary embodiment disclosed herein uses a TNM alloy and measures the corresponding change in current, but an ingot or charge made of a different metal or alloy (eg, dynamic or titanium-aluminum). Can have different current characteristics. Therefore, the calibration and operation of the melting system can vary based on the properties of the intermetallic compounds of the ingot formed in the system.

The systems and methods disclosed herein are applicable to standard size and reduced size ingots or ingots of any width / diameter produced in the industry. It can be further understood that the induction coils cast in the mold while present in the mold allow the monitoring of the heated ingot and its associated maneuvering. The system and method can be used to generate ingots of any length (constrained by the physical size of the system). The breadth of systems and methods can be applied across industry. This is because precise control of the position of the ingot in the mold for ingots of any size can help optimize the particle structure and / or surface finish of the as-cast ingot.

The system, and in particular the control interface, may include a microprocessor, which may also be a component of a processing device capable of controlling the operation of furnace appliances and recording system measurements. The processing device may be communicably coupled to the non-volatile memory device via the bus. Non-volatile memory devices can include any type of memory device that retains the stored information when power is turned off. Non-limiting examples of memory devices include electrically erasable and programmable read-only memory (“ROM”), flash memory, or any type of non-volatile memory. In some aspects, at least some of the memory devices may include a non-transient medium or memory device, and the processing device may read instructions from the non-transient medium or memory device. Non-transient computer-readable media include electronic storage devices, magnetic storage devices, or other storage devices capable of providing computer-readable instructions or other program code to processing devices. obtain. Non-transient examples of non-transient computer-readable media include magnetic disks (s), memory chips (s), ROMs, random access memory (“RAM”), ASICs, and configurations. Includes (but is not limited to) processors, optical storage devices, and / or other media (computer processors may read instructions from them). Instructions are compilers and / or interpreters from code written in any suitable computer programming language, including, for example, C, C ++, C #, Java®, Python, Perl, Javascript®, etc. May include processor-specific instructions generated by.

The above description is exemplary and not limiting, and the invention deviates from the essential properties of the invention, as will be apparent to those skilled in the art who have come into contact with the present disclosure. Without, it can be embodied in other specific forms. For example, any of the aspects described above can be combined into one or several different configurations, each having a subset of the aspects. In addition, throughout the above description, for illustrative purposes, many specific details have been stated to provide a complete understanding of the invention. However, it may be apparent to those skilled in the art that these embodiments may be practiced without some of these particular details. These other embodiments are intended to be included within the spirit and scope of the present invention. Therefore, the disclosure of the present invention should therefore not be determined solely by reference to the statements above, but rather to reference the following pending claims along with the overall scope of their legal equivalents. Should be determined by.

Claims (19)

It is a vacuum metallurgical system, and the system is
A segmented mold having an input end and an extraction end receives the molten metal or alloy, and the mold segmented is configured to cast into ingots,
A primary heating induction coil that is at least partially positioned around the segmented mold and is configured to induce heat within the internal region of the segmented mold. ,
A heating power source that is electrically coupled to the primary heating induction coil and supplies electric power to the primary heating induction coil.
A tuning capacitor configured to tune at least the primary heating induction coil and the electrical circuit containing the heating power source, with optimal power levels for melting the metal or alloy within the segmented mold. With a tuning capacitor that is further configured to
With at least one sensing coil located at least partially around the electrical conductor between the tuning capacitor and the primary heating induction coil.
And the ingot position actuator positioned so as to support and move the ingot and / or molten metal or alloy in said segmented in the mold,
An ingot position controller operably coupled in series between the at least one sensing coil and the ingot position actuator , wherein the ingot position controller detects a change in current detected by the at least one sensing coil. and measuring, is configured to melting metal or alloy performed and that instructs the ingot position actuator to move in a mold that is the segmented, and a ingot position controller, the system .. The system of claim 1, further comprising a material supply configured to provide the metal and / or alloy in either or both solid and melt forms to the input end of the segmented mold. .. The material supply
A crucible positioned in the vicinity of the input end of the segmented mold, the crucible being configured to provide a molten metal or alloy into said segmented mold,
A crucible heating system configured to melt a metal or alloy in the crucible.
Wherein the crucible heating system a secondary power source which is electrically coupled, further comprising a secondary power source and you power to the crucible heating system, according to claim 2 system. The crucible heating system, movable plasma arc torch, the electron beam gun, the secondary heating induction coil, or further combinations thereof, according to claim 3 system. The system of claim 1, wherein the segmented mold has segmentation that is oriented vertically and extends along the main axis of the segmented mold. The at least one sensing coil transfers any or both of the current amplitudes and current frequencies detected in the electrical conductor between the heating power source and the at least one primary heating induction coil to the ingot position controller. The system according to claim 1, which is configured to convert to an electrical control signal provided. The electrical control signal of the sensing coil is such that the top of the ingot is positioned near the primary heating induction coil, thereby moving the ingot within the segmented mold so that it is melted. 6. The system of claim 6, which is used by the ingot position controller to automatically steer the ingot position actuator. The electrical control signal of the sensing coil is such that the top of the ingot is positioned near the primary heating induction coil, thereby moving the ingot within the segmented mold so that it is melted. 6. The system of claim 6, which is used through operator interaction to steer the ingot position actuator. The system of claim 1, wherein the segmented mold has a cross-sectional area of 45.81 square centimeters ( 7.1 square inches ) or less. The system of claim 1, wherein the segmented mold has a width of 7.62 centimeters ( 3 inches ) or less. A method for determining the position of an ingot in a mold of a vacuum metallurgical system.
The metal and / or alloy is provided in a segmented mold, wherein the segmented mold is an open top and open bottom mold.
By heating the metal and / or alloy in the segmented mold with a heating induction coil , the heating induction coil and high frequency power supply are electrically connected to a tuning capacitor and said tuning. The capacitor is further configured to optimize the power level for melting the metal or alloy within the segmented mold .
And that the molten metal and / or alloy is maintained in the molten state, by dissolving any solid portion of the metal and / or alloy in the mold which is the segmented into a molten state,
And forming an ingot in the segmented within the mold with the molten metal and / or alloy,
The sensing coil is used to determine the position of the ingot in the segmented mold, the sensing coil being connected in series with an electronic position controller, the electronic position controller being the said. A method that is positioned between a tuning capacitor and the heating induction coil and is configured to measure changes in current detected by the sensing coil . Before SL method,
To optimize the power levels for dissolution in the mold which is the segmented, to tune the electrical circuit including the heating induction coil and the segmented mold and its contents and the high frequency power supply The method of claim 11, further comprising: The sensing coil is configured to detect the current in the conductor between the tuning capacitor and the heating induction coil, current through the heating induction coil and the tuning capacitor, Oite proportional to the sensing coil The method of claim 12, wherein the current or frequency of the coil is induced. The method is
The electronic position controller converts the current detected in the sensing coil into an electrical control signal.
And instruct the ingot position actuator to move the ingot before Symbol segmented within the mold in the vicinity of the heating induction coil,
11. The method of claim 11 , further comprising keeping the top of the ingot in a molten state. 14. The method of claim 14, wherein the electronic position controller commands the ingot position actuator via operator interaction. 14. The method of claim 14, wherein the electronic position controller commands the ingot position actuator via an automatic feedback loop. The method is
The electronic position controller converts the current detected in the sensing coil into an electrical control signal.
11. The method of claim 11 , further comprising varying the degree to which the metal and / or alloy in the segmented mold is heated by adjusting the power supplied to the heating induction coil. The method, based on the determined position of the ingot of the segmented within the mold, adjusting the injection rate of molten metal and / or alloy into said segmented mold The method of claim 11, further comprising. 11. The method of claim further comprises recovering the ingot from the segmented mold, wherein the ingot has a cross-sectional area of 45.81 square centimeters (7.1 square inches) or less. the method of.